Self-Removing Plug for Pressure Isolation in Tubing of Well

ABSTRACT

A downhole apparatus for use in a tubular include a mandrel, a first slip, a cone, and a seal element. The mandrel, which can be permanent or temporary, has a first end shoulder. The first slip is disposed on the mandrel adjacent the first end shoulder, and the cone is disposed on the mandrel adjacent the first slip. The cone is movable relative to the first end shoulder to engage the first slip toward the tubular. The seal element is disposed on the mandrel adjacent the cone. At least a portion of the seal element is composed of a dissolvable metallic material and is expandable outward from the mandrel. The expanded portion of the seal element forms a metal seal against the tubular and seals off fluid communication in the annular space between the seal element and the tubular.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Prov. Appl. No. 62/183,551,filed 23-Jun. 2015; 62/252,945, filed 9 Nov. 2015; and 62/303,121, filed3 Mar. 2016, each of which is incorporated herein by reference in itsentirety.

BACKGROUND OF THE DISCLOSURE

In wellbore construction and completion operations, a wellbore is formedto access hydrocarbon-bearing formations (e.g., crude oil and/or naturalgas) by drilling a wellbore. Drilling is accomplished by utilizing adrill bit that is mounted on the end of a drill string. To drill thewellbore to a predetermined depth, the drill string is often rotated bya top drive or rotary table on a surface platform or rig, and/or by adownhole motor mounted towards the lower end of the drill string.

After drilling to the predetermined depth, the drill string and drillbit are removed and a section of casing is lowered into the wellbore. Anannulus is thus formed between the string of casing and the formation,as the casing string is hung from the wellhead. A cementing operation isthen conducted to fill the annulus with cement. The casing string iscemented into the wellbore by circulating cement into the annulusdefined between the outer wall of the casing and the borehole. Thecombination of cement and casing strengthens the wellbore andfacilitates the isolation of certain areas of the formation behind thecasing for the production of hydrocarbons.

Once the casing has been cemented, the casing may be perforated to gainaccess to the surrounding formation. For example, the casing andsurrounding cement are perforated with holes or perforations tocommunicate the casing with the surrounding formation. Using suchperforations, operators can perform any number of operations, such ashydraulic fracturing or dispensing acid or other chemicals into theproducing formation. Additionally, the perforations can be used forproduction flow into a producing string disposed in the casing duringproducing operations.

Several techniques are currently used to produce perforations in casingand create a flow path. Most of the techniques require a workover rig ora coiled tubing (CT) unit to be used. “Plug-and-perf” is a commontechnique used to perforate and treat wells with cemented casing. Inthis technique, an isolation plug is run on wireline along with asetting tool and perforating gun(s) into the cemented casing. The plugis set in the casing with the setting tool, and the perforating gun(s)are used perforate the casing. The running tool and perforating gun(s)are then removed, a ball is deployed to the set plug, and fracturetreatment is pumped downhole to the newly created perforations. Whentreatment of this stage is finished, plug and perforation tools areinstalled for the next zone to be plugged, perforated, and then treated.Details of such a system are disclosed in U.S. Pat. No. 6,142,231, forexample.

The isolation plugs may be retrievable, and retrieval operations canremove the retrievable plugs so production and the like can commence.Alternatively, the isolation plugs may be expendable and composed of acomposite material. Once treatment operations are completed, the variousplugs left inside the casing can be milled out in a milling operation.As will be appreciated, retrieving the plugs and milling out the plugscan both take a considerable amount of time and can increase operationcosts.

For these reasons, operators have developed isolation plugs that aredissolvable. For example, Magnum Oil Tools offers a Magnum VanishingPlug™ (MVP™) composite frac plug that is engineered to dissolve in thecommon temperature and pressure ratings downhole so that flowback in thetubing can be established without the need for milling.

Schlumberger offers the Infinity Dissolvable Plug-and-Perf System thatuses degradable fracturing balls and seats to isolate zones duringstimulation. In this system, receptacles are initially run downhole onthe casing and cemented with the casing in the wellbore. To perform plugand perf operations, a seat is run downhole on a perforating gun. Whenpositioned near the location on the casing for the seat to be set, asetting tool activates the seat so that it will engage in the receptaclewhen moved further downhole. The seat is left in the receptacle as theperforating gun is raised and used to make perforations in the casing.After the gun is removed, a dissolvable ball is then deployed to theseat, and treatment fluid is pumped into the formation through theperforations. Operations on additional stages can also be performed.Eventually, the balls and seats remaining in the casing will dissolve.Examples of such a system are disclosed in U.S. Pat. No. 9,033,041, US2014/0014371, and US 2014/0202708.

The subject matter of the present disclosure is directed to overcoming,or at least reducing the effects of, one or more of the problems setforth above.

SUMMARY OF THE DISCLOSURE

According to the present disclosure, a downhole apparatus for use in atubular comprises a mandrel, a first slip, a cone, and a seal element.The mandrel, which can be permanent or temporary, has a first endshoulder. The first slip is disposed on the mandrel adjacent the firstend shoulder, and the cone is disposed on the mandrel adjacent the firstslip. The cone is movable relative to the first end shoulder to engagethe first slip toward the tubular.

The seal element is disposed on the mandrel adjacent the cone. At leasta portion of the seal element is composed of a dissolvable metallicmaterial and is expandable outward from the mandrel. The expandedportion of the seal element forms a metal seal against the tubular andseals off fluid communication in the annular space between the sealelement and the tubular.

In an arrangement where the mandrel is temporary, the first end shoulderis disposed on the mandrel and is removable therefrom in response to apredetermined load. In this way, the mandrel freed of the first endshoulder is removable from the slip, the cone, and the seal element.With the mandrel removed, the seal element can define a seating areaengageable by a plug deployed down the tubular to the apparatus.Alternatively, the cone can define a seating area engageable by such aplug.

In an arrangement where the mandrel is permanent, the first end shoulderis disposed toward a first (e.g., downhole) end of the mandrel, and themandrel has a second end shoulder disposed at a second (e.g., uphole)end adjacent the seal element. The mandrel defines a through-bore fromthe first end to the second end, and the second end defines a seatingarea about the through-bore for engaging a deployed plug.

In a first arrangement for the seal, the seal element includes first andsecond rings disposed on the mandrel and movable longitudinally thereon.An expansion ring is disposed on the mandrel between the first andsecond rings and expands radially outward with the longitudinal movementof the first and second rings toward one another. This expansion ringcan be composed of the dissolvable metallic material and can form themetal seal against the tubular. To enhance the metal seal, the expansionring can define an external surface disposed circumferentiallythereabout and engageable toward the tubular. This external surface canhaving a plurality of fins extending therefrom.

In a second arrangement for the seal, the seal element can include thefirst and second rings and the expansion ring and can further include asheath disposed circumferentially about at least the expansion ring. Thesheath deforms outward toward the tubular with the radial expansion ofthe expansion ring. This sheath can be composed of the dissolvablemetallic material and can form the metal seal against the tubular. Infact, the first and second rings, the expansion ring, and the sheath caneach be composed of a reactive metal. If desired, a sealing ring canbonded circumferentially about the sheath and can be engageable againstthe tubular.

For this form of the second seal, the first ring can be integrally partof the cone. The sheath can have one or more lips extending at leastbetween the first ring and the cone, at least between the second ringand a push ring disposed on the mandrel, or between the first ring andthe cone as well as the second ring and the push ring.

The features of the first and second rings and the expansion ring in thefirst and second seals can have a number of variations. In one example,the first ring defines a first inclined face, and the second ringdefines a second inclined face opposing the first inclined face. Theexpansion ring has first and second inclined sides disposed respectivelyagainst the first and second inclined faces. The expansion ring caninclude first and second split rings interlocked together and eachhaving one of the first and second inclined sides. Moreover, anelastomeric material can be disposed about, on, or between one or moreof the first and second rings, the expansion ring, and the split ringsto enhance sealing.

For instance, a first elastomeric element can be disposed adjacent thefirst inclined face of the first ring and can be engageable with thefirst side of the expansion ring. Alternatively or in addition, a secondelastomeric element can disposed adjacent the second inclined face ofthe second ring and can be engageable with the second side. Furthermore,the first elastomeric element can have a lip disposed in an edge of thefirst ring and at least partially engaging the mandrel. Also, the secondinclined face of the second ring can define a cutaway accommodating thesecond elastomeric element. These and other enhancements can be made forsealing off fluid communication.

On the mandrel, a second slip can be disposed adjacent the second ringof the seal element. A second end shoulder, such as a push ring, bodylock ring, or the like, can be disposed on the mandrel adjacent thesecond slip and can moved toward the first end shoulder to engage thesecond slip toward the tubular.

In a third arrangement of the seal, the seal element includes a pushring, an expansion rings, and a sheath. The push ring is disposed on themandrel and is movable longitudinally thereon. The expansion ring isdisposed on the mandrel between the push ring and an inclined face ofthe cone. The expansion ring expands radially outward with thelongitudinal movement of the push ring and the cone toward one another.The sheath is disposed circumferentially about at least the expansionring and has a lip extending at least toward the push ring. The sheath,which is composed of the dissolvable metallic material, deforms outwardtoward the tubular with the radial expansion of the expansion ring toform the metal seal of the apparatus.

In a fourth arrangement of the seal, the seal element is disposed aboutthe cone and disposed against an end of the first slip. The seal elementis expandable along an incline of the cone when force longitudinallythereon. In one example, the first slip is disposed against a firstincline of the cone, and the seal element is disposed about a secondincline of the cone opposed to the second incline so that the sealelement is expandable along the second incline of the cone. (FIG. 5A,7A, 8A).

In one configuration, the mandrel defines a first incline, and the sealelement is expandable along the first incline of the mandrel. The conedefines a second incline opposing the first incline. A setting elementdisposed between the first slip and the seal element concurrentlyexpands the first slip and the seal element along the respective inclineand is frangible in response to a predetermined load thereagainst.

The seal element in this fourth seal can include a swage seal having aring body and having inner and outer seal members. The ring body iscomposed of the dissolvable metallic material. The inner and outer sealmembers are disposed respectively about the inner and outercircumferences of the ring body and can be composed of a degradableelastomer or the like.

In a fifth arrangement of the seal, the seal element includes first andsecond rings and a push ring. The first ring is disposed on the mandreladjacent the cone, and the second ring is disposed on the mandreladjacent the first ring. The first ring has first petals flexibleoutward therefrom, and the first ring has a lip disposed at leastpartially between the cone and the mandrel. The second ring also hassecond petals flexible outward therefrom.

The push cone is disposed on the mandrel adjacent the second ring and ismoveable longitudinally on the mandrel toward the first end shoulder.The first and second petals of the first and second rings are offsetfrom one another and expand radially outward to seal against thetubular. To enhance sealing, at least one or more of the first ring,second ring, and push cone can have a coating of elastomeric material.

In another arrangement where the mandrel is permanent, the mandrel is anexpandable sleeve. The first slip and the seal element are disposed onan outer surface of the expandable sleeve. The cone is disposed in theexpandable sleeve, and the cone is movable toward the first end shoulderto expand the expandable sleeve and engage the first slip and the sealelement toward the tubular.

For this arrangement, the first end shoulder of the mandrel can be an atleast partially closed end of the expandable sleeve, and the cone canhave a portion sealably engaging the at least partially closed end.Alternatively, the cone can be removable from the expandable sleeve, andthe first end shoulder is a closed end of the expandable sleeve.

According to the present disclosure, the downhole apparatus for use inthe tubular can include one or more of a perforating gun and a runningtool. The running tool can move mandrel and components of cone, firstslip, and seal element relative to one another to set in the tubular.The running tool may release from the mandrel when permanent or maywithdraw the mandrel when temporary from the set components. Theperforating gun can be run into the tubular and can operable toperforate the tubular. The running tool can be run separately from theperforating gun, or they can be run together. For example, the runningtool can extend from the perforating gun and can be temporarilyaffixable to the apparatus.

According to the present disclosure, the dissolvable metallic materialcan be a reactive metal; a magnesium alloy; or calcium, magnesium, andaluminum including alloying elements of calcium, magnesium, aluminum,lithium, gallium, indium, zinc, and bismuth. One or more components ofthe apparatus other than the seal element can be composed of one or moreof a reactive metal, a degradable composite polymer, a self-removingmaterial, and an elastomeric material.

The foregoing summary is not intended to summarize each potentialembodiment or every aspect of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1C illustrate cross-sectional views of a first self-removingplug according to the present disclosure during stages of setting intubing.

FIG. 1D illustrates a perspective view of the first self-removing plugin cross-section.

FIGS. 1E-1 and 1E-2 illustrate details of the setting sleeve, bodyrings, and expansion element or rings for the disclosed plug.

FIGS. 1F-1, 1F-2, and 1F-3 illustrate details of the expansion elementor rings for the disclosed plug.

FIGS. 2A-2C illustrate cross-sectional views of a second self-removingplug with a mandrel according to the present disclosure during stages ofsetting in tubing.

FIG. 2D-2E illustrate perspective views of the second self-removing plugin cross-section and in full.

FIGS. 3A-3C illustrate cross-sectional views of a third self-removingplug according to the present disclosure during stages of setting intubing.

FIGS. 3D-3E illustrate perspective views of the third self-removing plugin cross-section and in full.

FIGS. 4A-4C illustrate cross-sectional views of a fourth self-removingplug with a mandrel according to the present disclosure during stages ofsetting in tubing.

FIGS. 4D-4E illustrate perspective views of the fourth self-removingplug in cross-section and in full.

FIGS. 5A-5C illustrate cross-sectional views of a fifth self-removingplug according to the present disclosure during stages of setting intubing.

FIGS. 5D-5E illustrate perspective views of the fifth self-removing plugin cross-section and in full.

FIGS. 6A-6B illustrate cross-sectional views of a sixth self-removingplug according to the present disclosure during stages of setting intubing.

FIGS. 7A-7B illustrate cross-sectional views of a seventh self-removingplug according to the present disclosure during stages of setting intubing.

FIGS. 8A-8B illustrate cross-sectional views of an eighth self-removingplug according to the present disclosure during stages of setting intubing.

FIGS. 9A-9B illustrate cross-sectional views of a ninth self-removingplug according to the present disclosure during stages of setting intubing.

FIGS. 10A-10B illustrate cross-sectional views of a tenth self-removingplug according to the present disclosure during stages of setting intubing.

FIGS. 11A-11B illustrate cross-sectional views of an eleventhself-removing plug according to the present disclosure during stages ofsetting in tubing.

FIGS. 12A-12B illustrate cross-sectional views of a twelfthself-removing plug according to the present disclosure during stages ofsetting in tubing.

FIGS. 13A-13B illustrate cross-sectional views of a thirteenthself-removing plug according to the present disclosure during stages ofsetting in tubing.

FIGS. 14A-14C illustrate steps of an example plug-and-perf operationwith the disclosed self-removing plugs.

FIG. 15 illustrates a step of another example plug-and-perf operationwith the disclosed plugs.

FIG. 16 illustrates the wellbore after dissolution of the disclosedplugs.

FIGS. 17A through 18B illustrate cross-sectional views of anotherself-removing plug with a mandrel according to the present disclosureduring stages of setting in tubing.

FIG. 19 illustrates the self-removing plug used in casing of a differentweight.

FIGS. 20A-20B illustrate details of expansion rings disposed betweencones on the mandrel for the disclosed plug.

FIGS. 21A-21B illustrate isolated perspective views of expansions ringsfor the disclosed plug.

FIG. 22 illustrates an embodiment of a plug having features to helpaccelerate the corrosion rate.

FIG. 23 illustrate a cross-sectional view of a self-removing plug withadditional sealing for the expansion rings according to the presentdisclosure.

FIGS. 24A-24C illustrate cross-sectional views of a self-removing plugwith additional sealing for the expansion rings according to the presentdisclosure during stages of setting in tubing.

FIG. 25 illustrates a cross-sectional view of components for molding theadditional sealing for the expansion rings.

FIGS. 26A-26D illustrate the molding process of the additional sealingfor the expansion rings.

FIGS. 27A-27C illustrate cross-sectional views of alternativeself-removing plugs with additional sealing for the expansion ringsaccording to the present disclosure.

FIGS. 28A-28B illustrate views of a self-removing plug with alternativesealing system according to the present disclosure.

FIG. 29 illustrates an isolated view of the components of thealternative sealing system.

FIGS. 30A-30C illustrate various embodiments of slips for the disclosedplugs.

DETAILED DESCRIPTION OF THE DISCLOSURE

FIGS. 1A-1C illustrate cross-sectional views of a first self-removingplug 100 according to the present disclosure during stages of setting intubing, such as cemented casing 10. FIG. 1D illustrates a perspectiveview of the first self-removing plug 100 in cross-section. The plug 100includes a cone 110, a slip 120, and a seal element (having a sealingsleeve or sheath 130, body rings 140A-B, and expansion element or rings150A-B).

This plug 100 (as well as the other plugs disclosed herein) isself-removing. For example, the various components of this plug 100 andthe others disclosed herein can be composed of a dissolvable material.In one embodiment, such a dissolvable material can include a reactivemetal, such as a magnesium alloy. One particular magnesium alloy isSoluMag™ available from Magnesium Elektron Alloys. Other reactivemetals, such as calcium, magnesium, aluminum, can be used and caninclude alloying elements of calcium, magnesium, aluminum, lithium,gallium, indium, zinc, or bismuth. For example, the cone 110, slip 120,sealing sleeve 130, body rings 140A-B, and expansion rings 150A-B can becomposed of such reactive metals. If used on the disclosed plug 100,slip inserts 124 can be composed of ductile iron, while any seals,pump-down rings, etc. can be composed of elastomer. In oneconfiguration, the slip 120, the sealing sleeve 130, and the expansionrings 150A-B are manufactured from a ductile/high elongation dissolvablematerial. The material's elongation properties can be in the range of18-28%, but can be slightly more or less. Other components can besimilarly configured.

In addition to using dissolvable material for the disclosed plugs 100,other self-removing materials can be used. For example, the material forthe various components can be composed of a degradable compositepolymer, such as available from Bubbletight, LLC. Still other materialscan be used that are dissolvable, degradable, corrodible, biodegradable,combustible, erodible, etc. so that the disclosed plugs 100 can beself-removing. Some examples of such materials include polyglycolic acid(PGA), a pyrotechnic composition, natural stone (e.g., limestone), awater-reactive agent, a hydrocarbon soluble material, etc.

All of the components can be composed of a similar material, ordifferent combinations of the various materials can be used. In terms ofthe present disclosure, reference to removing of a self-removingmaterial (e.g., dissolving of dissolvable material and the like) canrefer to a number of activities for various materials, includingcorroding, disintegrating, melting, degrading, biodegrading, eroding,combusting, etc. of material under existing well conditions, after aperiod of time, and/or in response to an introduced medium or trigger(e.g., acid, temperature, chemical substance, solvent, enzyme, pressure,water, hydrocarbon, etc.).

For run in as shown in FIG. 1A, a running tool 20 has an outer settingsleeve 22 disposed about an inner setting tool 24. (This running tool 20can be run alone on wireline or other conveyance or can be run with aperforating gun assembly on wireline or the like.) The components 110,120, 130, 140A-B, and 150A-B of the disclosed plug 100 fit on a run-inmandrel 26, which may be composed of steel and is connected to the innertool 24. (Thus, during run-in, the mandrel 26 acts as part of the plug100, but the mandrel 26 is removable once the plug 100 is set asdiscussed below.) A mule shoe 28 is affixed on the end of the run-inmandrel 26 to hold the plug 100 in place. A temporary connection, suchas a shearable thread 27, holds the mule shoe 28 on the run-in mandrel26 until setting procedures are complete, as discussed later. Othertemporary connections could be used to hold the mule shoe 28 on themandrel 26.

The cone 110 of the plug 100 has an incline 112 against which the slip120 can wedge. The other end of the slip 120 abuts against the mule shoe28, which is used to push the slip 120 on the incline 112 duringsetting.

The sealing sleeve 130 has a lip 132 of increased thickness and widththat fits around the run-in mandrel 26 like a ring and abuts against thecone 110. A thin sheath 134 of the dissolvable material of the sealingsleeve 130 extends from this lip 132 so that the lip 132 acts as ananchor for the thin sheath 134 as it runs along the outside of the plug100. Disposed within this sheath 134 around the run-in mandrel 26, theplug 100 has its body rings 140A-B and expansion rings 150A-B. The bodyrings 140A-B sandwich the expansion rings 150A-B, and each abuttingcorner of these rings 140, 150 can have angled edges.

FIGS. 1E-1 and 1E-2 illustrate details of the sealing sleeve 130, thebody rings 140A-B, and the expansion element or rings 150A-B for thedisclosed plug 100. The sleeve 130 and rings 140A-B, 150A-B each havecentral passages 142, 152, 131 for fitting on a mandrel (not shown). Therings 140A-B, 150A-B have angled edges 144, 154. As shown, the expansionrings 150A-B preferably includes two adjacent split C-rings that canslide relative to one another as they expand outward. The splits 156 inthese rings 150A-C are misaligned so that the two split rings 150A-Btogether form a complete ring.

FIGS. 1F-1, 1F-2, and 1F-3 illustrate alternative details of theexpansion element or rings for the disclosed plug. Instead of the splitrings 150A-C discussed above and shown in FIG. 1F-1, the expansionelement can be a ring 150′ of elastomer or other deformable material, asillustrated in FIGS. 1F-2 and 1F-3.

During run-in as shown in FIG. 1A, the plug 100 is held on the run-inmandrel 26 uncompressed. The running tool 20 is coupled to an actuator(not shown) used for activating the setting tool 20 and setting the plug100. During activation, the setting sleeve 22 pushes against the bodyring 140B, while the inner setting tool 24 pulls the run-in mandrel 26in the opposite direction. As a result, the mule shoe 28 concurrentlypushes against the slip 120, and the components of the plug 100 arecompressed.

As shown in FIG. 1B, the slip 120 is pushed up the incline 112 andwedged against the inside wall 12 of the casing 10. The slip 120 can bea continuous cylindrical shape with separable splits, cuts, or the likeformed therein, can be independent segments, or can have some otherknown configuration. At the same time, the body rings 140A-B are broughttogether, and the expansion rings 150A-B are forced outward toward thesurrounding casing 10. The sheath 134 bulges outward by being deformedby the expansion ring 150A-B and forms a metal-to-metal seal with theinner casing wall 12.

Eventually, the setting force shears the mule shoe 28 free from therun-in mandrel 26 so that the setting tool 20 is released from the plug100, which is now set in the casing 10. The mule shoe 28 can falldownhole where it can dissolve, and the setting tool 20 can be retractedfrom the casing 20. The plug 100 is now ready for use.

As shown in FIG. 1C, the plug 100 remains set with the seal elementexpanded. As noted, the components of the seal element, e.g., thesealing sleeve 130, the expansion rings 150A-B, and the like, arecomposed of a dissolvable metallic material, which can be ductile andhave elongation properties and which can remain expanded after setting.

As then shown in FIG. 1C, a ball B or other plugging element can bedeployed to the plug 100 to seat against the seating surface 146 of thebody ring 140B. Pressure for a fracture treatment can be applied againstthe plug 100 with the seated ball B, which prevents the treatment frompassing to zones further downhole. (Although a ball B is shown andreferenced throughout this disclosure, other types of plugging elementsB can be used, including darts, cones, etc., known and used in the art.Therefore, reference to a ball B as used herein refers equally to anyother acceptable plugging element.) The pressure against the seated ballB on the set plug 100 can further act to seal the plug's seal elementagainst the casing with the slip 120 helping anchor the plug 100 inplace.

FIGS. 2A-2C illustrate cross-sectional views of a second self-removingplug 100 according to the present disclosure during stages of setting intubing 10, and FIG. 2D-2E illustrate perspective views of the secondself-removing plug 100 in cross-section and in full. This plug 100 issimilar to that disclosed above with reference to FIGS. 1A-1D so thatlike reference numerals are used for similar components. In contrast tothe previous embodiment, this plug 100 includes a mandrel 160 thatremains with the plug 100 after setting.

On this plug 100, the permanent mandrel 160 is attached to the innersetting tool 24 of the running tool 20 with a temporary connection, suchas a shearable or releasable thread 164. With the setting forcesapplied, the running tool 20 can eventually shear free of the permanentmandrel 160 which remains as part of the plug 100.

In other differences, the plug 100 includes one or more seals on thering components and the mandrel 160 to prevent fluid bypass. Forexample, the lip 132 of the sealing sleeve 130 can have an O-ring seal133 on its inner diameter to seal against the mandrel 160. As anotherdifference, a contact ring 170 can be disposed on the mandrel 160against which the setting sleeve 22 presses during setting procedures.

FIGS. 3A-3C illustrate cross-sectional views of a third self-removingplug 200 according to the present disclosure during stages of setting intubing, and FIGS. 3D-3E illustrate perspective views of the thirdself-removing plug 200 in cross-section and in full. The plug 200includes a wedge body or cone 210, a slip body or slip 220, and a sealelement or swage seal 230. Each of these components can be composedprimarily of a dissolvable material, such as a reactive metal asdisclosed herein.

For run-in as shown in FIG. 3A, a running tool 20 has an outer settingsleeve 22 disposed about an inner setting tool 24. The components 210,220, and 230 of the plug 200 fit on a run-in mandrel 26, which can becomposed of steel and is connected to the inner tool 24. (Again, thisrun-in mandrel 26 is not permanent and can be removed once the plug 200is set as discussed below.) A mule shoe 28 composed of a dissolvablematerial is affixed on the end of the run-in mandrel 26 to hold the plug200 in place. A temporary connection, such as a shearable thread 27,hold the mule shoe 28 on the run-in mandrel 26 until setting proceduresare complete, as discussed later.

The wedge body 210 of the plug 200 has the form of a cone having anincline 212 against which the slip body 220 can wedge. The other end ofthe slip body 220 abuts against the mule shoe 28, which is used to pushthe slip body 220 on the incline 212 during setting.

The swage seal 230 is disposed on the incline 212 of the wedge body 210.In general, the swage seal 230 is a seal element having a ring body 232,which can be composed of dissolvable metal. Internal and external sealmembers 234 can be disposed about the inner and outer dimensions of thering body 232. These seal members 234 can be elastomer, soft metal,polymer, etc.

During run-in as shown in FIG. 3A, the plug 200 is held on the run-inmandrel 26 uncompressed. The running tool 20 is coupled to an actuator(not shown) used for activating the setting tool 20 and setting the plug200. During activation, the setting sleeve 22 pushes against the wedgebody 210, while the inner setting tool 24 pulls the run-in mandrel 26 inthe opposite direction. As a result, the mule shoe 28 concurrentlypushes against the slip body 220, and the components of the plug 200 arecompressed.

As shown in FIG. 3B, the slip body 220 is pushed up the incline 212 andwedged against the inside wall 12 of the casing 10. At the same time,the inserts 224 in the slip body 220 bite into the casing wall 12, andthe swage seal 230 is expanded outward toward the surrounding casing 10.As shown in FIG. 3E, the slip body 220 can have one or more slits 221(i.e., divisions, cuts, or the like) that make the body 220 separable orexpandable into one or more segments. For example, the slip body 220 canhave one slit 221 so that the body 220 can expand outward as a partialcylinder when wedged by the wedged body 210. Alternatively, the slipbody 220 can have more slits 221 so it can separate into varioussegments.

Eventually, the setting force shears the mule shoe 28 free from therun-in mandrel 26 so that the setting tool 20 is released from the plug200, which is now set in the casing 10. The mule shoe 28 can falldownhole where it can dissolve, and the setting tool 20 can be retractedfrom the casing 20. The plug 200 is now ready for use. As shown in FIG.3C, a ball B or the like can be deployed to the plug 200 to seat againstthe seating surface 216 of the wedge body 210. Pressure for a fracturetreatment can be applied against the plug 200 with the seated ball B,which prevents the treatment from passing to zones further downhole.Pressure against the seated ball B can tend to further wedge the plug200. This may be true not only for this plug 200, but the other plugsdisclosed herein.

FIGS. 4A-4C illustrate cross-sectional views of a fourth self-removingplug 200 with a mandrel 260 according to the present disclosure duringstages of setting in tubing, and FIGS. 4D-4E illustrate perspectiveviews of the fourth self-removing plug 200 in cross-section and in full.This plug 200 is similar to that disclosed above with reference to FIGS.3A-3E so that like reference numerals are used for similar components.In contrast to the previous embodiment, this plug 200 includes themandrel 260 that remains with the plug 100 after setting.

With this plug 200, the permanent mandrel 260 is attached to the innersetting tool 24 of the running tool 20 with a temporary connection, suchas a shearable or releasable thread 264. With the setting forces, therunning tool 20 shears free of the permanent mandrel 260 which remainsas part of the plug 200. In other differences, the plug 200 includes oneor more seals on the ring components and the mandrel 260 to preventfluid bypass. For example, the inside of the wedge body 210 can have anO-ring seal 213 on its inner diameter to seal against the mandrel 260.

FIGS. 5A-5C illustrate cross-sectional views of a fifth self-removingplug 200 according to the present disclosure during stages of setting intubing, and FIGS. 5D-5E illustrate perspective views of the fifthself-removing plug 200 in cross-section and in full. This plug 200 issimilar to that disclosed above with reference to FIGS. 3A-3E so thatlike reference numerals are used for similar components. In contrast tothe previous embodiment, the seal element or swage seal 230 is placed onan opposing incline 214 than the incline 212 for the slip body 220.

Additionally, setting procedures use a different setting tool 20 becausethe swage seal 230 is moved separately on the wedge body 210. Inparticular, the swage seal 230 is initially installed on the proximalend of the wedge body 210 near the connection of the setting tool 20.The setting sleeve 22 of the tool 20 has a collet 23 that engages theswage seal 230 to force the seal 230 along the incline 214 and to expandduring this process.

It will be apparent based on the teachings of FIGS. 3A through 5E thatyet an additional embodiment of the present disclosure can use thecomponents of the plug 200 in FIGS. 5A-5E with a permanent mandrel 260as disclosed in the examples of FIGS. 4A-4E. Such an arrangement isbriefly shown in FIG. 5F.

FIGS. 6A-6B illustrate cross-sectional views of a sixth self-removingplug 300 according to the present disclosure during stages of setting intubing. The plug 300 includes a housing or mandrel 340 that defines abore 342 therethrough. A distal end of the housing 300 can have apump-down ring 341. A seal element or swage seal 330 is disposed aboutthe housing 340 near an external incline 344, and a slip 310 disposedabout the housing 340 fits against the swage seal 330 with a settingring 360. The slip 310 can include a continuous ring with separabledivision or can include several segments (not shown) held about thehousing 340 with bands (not shown), although other configurations arepossible.

A cone 350 disposed about the housing 340 at its proximal end has anincline 352 for engaging the slip 310. A body lock ring 356 or otherratchet mechanism can control the movement of the cone 350 along theoutside of the housing 340 during setting.

A setting tool (20) can run the plug 300 downhole. A lock profile 345inside the housing's bore 342 may be provided for engagement by a key ofan inner tool (24). Meanwhile, the setting tool (20) can have an outersleeve (22) engaging the cone 350 so that the cone 350 can be pushedfurther onto the housing 340. In this process, the cone 350 wedges theslip 310 outward to the casing 10 so that the inserts 314 bite into thecasing's wall 12.

While the cone 350 is moved, the body lock ring 356 prevents reversemovement along the housing 340. The slip 310 connected by the settingring 360 pushes the swage seal 330 along the incline 344 so that theswage seal 330 eventually wedges and seals against the casing wall 12.To prevent over wedging of the components, the setting ring 360 may befrangible and configured to break at a predetermined load. Additionally,the lock profile 345 on the housing 340 can be configured to fail at atensile load for setting so the setting tool (20) can be released fromthe plug 300. This can leave a seating area 346 for engagement of adropped ball B during later treatment steps.

FIGS. 7A-7B illustrate cross-sectional views of a seventh self-removingplug 300 according to the present disclosure during stages of setting intubing. This plug 300 is similar to that disclosed above with referenceto FIGS. 6A-6B so that like reference numerals are used for similarcomponents. In contrast to the previous embodiment, the seal element orswage seal 330 is placed on an opposing incline 354 of the cone 350 thanthe incline 352 for the slip 310.

As before, the plug 300 includes a housing or mandrel 340 that defines abore 342 therethrough. A distal end of the housing 300 can have an endring 348 with a pump-down ring 341 disposed around it. The swage seal330 is disposed about the cone 350 near the upper incline 354 of thecone 350, while the slip 310 is disposed near the lower incline 352 tofit against the end ring 348.

A setting ring 360 is disposed on the housing 340 and abuts against theswage seal 330. A body lock ring 356 or other ratchet mechanism on thesetting ring 360 can control the movement of the ring 360 along theoutside of the housing 340 during setting.

A setting tool (20) can run the plug 300 downhole. A lock profile 345inside the housing's bore 342 may be provided for engagement by a key ofan inner tool (24). Meanwhile, the setting tool (20) can have an outersleeve (22) engaging the setting ring 360 so that the ring 360 can bepushed further onto the housing 340. Abutting the setting ring 360, theswage seal 330 is moved along the incline 354 so that the swage seal 330eventually wedges and seals against the casing wall 12. To prevent overwedging of the components, the setting ring 360 may be frangible andconfigured to break at a predetermined load.

During these setting steps, the cone 350 can move along the housing 340and can wedge the slip 310 with the cone's incline 352 outward to thecasing 10 so that the inserts 314 bite into the casing's wall 12. Onemore seals 358 can be provided between the cone 350 and the housing 340to seal their interface. Also, the key profile 345 on the housing 340can be configured to fail at a tensile load for setting to release thesetting tool (20) from the plug 300. This can leave a seating area 346for engagement of a dropped ball B during later treatment steps.

FIGS. 8A-8B illustrate cross-sectional views of an eighth self-removingplug 300 according to the present disclosure during stages of setting intubing. This plug 300 is similar to that disclosed above with referenceto FIGS. 7A-7B so that like reference numerals are used for similarcomponents. In contrast to the previous embodiment, this plug 300 lacksseparate housing/mandrel and cone component, and this plug 300 is setusing a temporary mandrel 26 and mule shoe 28.

The plug 300 includes a cone 350 (which is a combined mandrel/housingand cone component) disposed on the setting tool's mandrel 26, which canhave a pump-down ring 341 on the mule shoe 28. A seal element or swageseal 330 is disposed about the cone 330 near an upper incline 354 of thecone 350, while a slip 310 is disposed near a lower incline 352 to fitagainst the mule shoe 28.

A setting tool (20) to run the plug 300 downhole has a sleeve 22 with acollet 23 engaging the swage seal 330 so that the swage seal 330 can bepushed further onto the cone's incline 354. During these setting steps,the cone 350 can move along the tool's mandrel 26 and can wedge the slip310 with the cone's incline 352 outward to the casing 10 so that theinserts 314 bite into the casing's wall 12.

Eventually, a breakable connection, such as shear threading 27 betweenthe mandrel 26 and mule shoe 28, can break free and allow the settingtool 20 and the mandrel 26 to be removed. As shown in FIG. 6B, a ball orother plugging element B can be deployed downhole to the cone 350 toseat in a seating area 355 so that treatment operations can commence.

FIGS. 9A-9B illustrate cross-sectional views of a ninth self-removingplug 400 according to the present disclosure during stages of setting intubing. The plug 400 includes a cone 410, a slip 420, and a seal element(having a sealing sleeve 430, body rings 440A-B, expansion element orrings 450A-B). The plug 400 also includes a mandrel 460, which isintended to remain with the plug 400 once set. Each of these componentscan be composed of a dissolvable metal, such as disclosed herein, andcan have similarities to like components disclosed in previousembodiments.

For run in, a running tool (20) having a setting sleeve (22) and aninner tool (24). The mandrel 460 of the plug 400 connects to the innertool (24) with a temporary connection, while the setting sleeve (22)abuts against a body lock ring 470 on the mandrel 460.

The cone 410 of the plug 400 has an incline 412 against which the slips420 can wedge. The other end of the slip 420 abuts against the end ring468 of the mandrel 460. The sealing sleeve 430 has lips 432 of increasedthickness and width that fit around the mandrel 460 like rings, and oneof these lips 432 abuts against the cone 410. A thin sheath 434 of thedissolvable material of the setting sleeve 430 extends between theselips 432, which act as anchors for the thin sheath 434 as it runs alongthe outside of the plug 400. Disposed within this sheath 434 around themandrel 460, the plug 400 has its body rings 440A-B and expansion rings450A-B. The body rings 440A-B sandwich the expansion rings 450A-B, andeach abutting corner of these rings 440, 450 can have angled edges. Asshown, the expansion element 450A-B is preferably two adjacent splitC-rings that can slide relative to one another as they expand outward.The splits (not shown) in these rings 450A-C are misaligned so that thetwo split rings 450A-B together form a complete ring.

During run-in as shown in FIG. 9A, the plug 400 is held on the settingtool (20), and the external components remain uncompressed on themandrel 460. The running tool (20) is coupled to an actuator (not shown)used for activating the setting tool (20) and setting the plug 400.During activation, the setting sleeve (22) pushes against the body lockring 470, while the inner setting tool (24) pulls the run-in mandrel(26) in the opposite direction. As a result, the mule shoe 468 on themandrel 460 can concurrently push the end ring 468 against thecomponents of the plug 400 to compress them.

As shown in FIG. 9B, the body lock ring 470 moves along the mandrel 460.The slip 420 is pushed up the incline 412 and wedged against the insidewall 12 of the casing 10. At the same time, the body rings 440A-B arebrought together, and the expansion rings 450A-B are forced outwardtoward the surrounding casing 10. The sheath 434 bulges outward by beingdeformed by the expansion ring 450A-B and forms a metal-to-metal sealwith the inner casing wall 12.

Eventually, the setting force shears the mandrel 460 free from the innertool (24) so that the setting tool (20) is released from the plug 400,which is now set in the casing 10. The setting tool (20) can beretracted from the casing 10. The plug 400 is now ready for use. Asshown in FIG. 9B, a ball B or the like can be deployed to the plug 400to seat against the seating surface 466 of the mandrel 460. Pressure fora fracture treatment can be applied against the plug 400 with the seatedball B, which prevents the treatment from passing to zones furtherdownhole.

The sheath 434 can be an annealed ring of thin walled material. A rubberor metallic element 436 can be bonded or attached on the outside of thesheath 434 to enhance sealing. Seals 433 can be provided on the lips 432to seal against the mandrel 460.

FIGS. 10A-10B illustrate cross-sectional views of a tenth self-removingplug 100 according to the present disclosure during stages of setting intubing. The plug 100 in FIG. 10A is similar to that disclosed above withreference to FIGS. 1A-1D so that like reference numerals are used forsimilar components. For the plug 100 of FIG. 10A, the end of the sheath130 can be attached to one of the body rings 140B with an electron beamor laser weld 138. The plug 100 in FIG. 10B is a reverse configurationof the first self-removing plug 100 of FIGS. 2A-2E. The lip 132 of thesheath 130 rests against a push ring 170 at the proximal end of theplug's housing 160. The cone 110 incorporates at one end 140A′ featuresof a body ring.

FIGS. 11A-11B illustrate cross-sectional views of an eleventhself-removing plug 500 according to the present disclosure during stagesof setting in tubing 10. The plug 500 includes an external body ormandrel 510 and an internal plug element or cone 550. The external bodyor mandrel 510 is an expandable sleeve, while the plug element or cone550 is an expansion cone or head to be left inside the external body510. Both the body 510 and plug element 550 can be composed of adissolvable material, as disclosed herein, and they can be composed ofthe same or different material. The exterior of the body 510 has asealing element 520 and an anchor element or slip 530. The sealingelement 520 can be composed of elastomer, metal, or the like that isdisposed, bonded, or affixed about the exterior of the body 510. Theanchor element or slip 530 can include slip members, carbide inserts,gripping material, etc. attached about the exterior of the body 510. Aseal 554 on the nose 552 of the plug element 550 can be composed ofelastomer or the like.

A setting tool 30 couples to the plug 500 and is used for running andsetting the plug 500 downhole in casing 10. The setting tool 30 includesa push rod 34 with a distal end engaged against the plug element 550. Apull rod 36 connects to a pull sleeve 38, and shearable connections 39connect the pull sleeve 38 to the plug's body 510. A crosslink 33connected to the proximal end of the push rod 34 rides in slots 37 ofthe pull sleeve 38 and connects to a push sleeve 32 of the setting tool30.

The pull rod 36 and push sleeve 32 connect to an actuator 40 of thesetting tool 30, which can pull the rod 36 and push the sleeve 32relative to one another. During this activation, the plug element 550 isforced through the inner passage 512 of the body 510, causing the body510 to expand outward toward the surrounding casing 10. The plug element550 is pushed into the narrower end of the body 510 at least until thesealing element 520 and anchor element 530 engage the surrounding casingwall 12, as shown in FIG. 11B. The nose 552 of the plug element 550eventually seals inside the narrow tip (or end shoulder) of the body510, which has an opening 514 through which excess fluid can escape.

The plug element 550 can be fitted with a body lock ring, a snap ring,or other retainer (not shown) to prevent the pushed plug element 510from being forced out of the body 510 in the opposite direction. Thismay allow the deployed plug 500 to seal the casing 10 as a bridge plug,preventing fluid flow in both uphole and downhole directions. Aftersetting and use, the components of the plug 500 can dissolve in themanner disclosed herein to remove the fluid isolation.

FIGS. 12A-12B illustrate cross-sectional views of a twelfthself-removing plug 500 according to the present disclosure during stagesof setting in tubing 10. This plug 500 is similar to that disclosedabove in FIGS. 11A-11B so that like reference numerals can be used forsimilar components. In contrast to the previous embodiment, this plug500 is expanded through a pulling action.

The plug 500 includes an external body or mandrel 510 and a plug elementor end shoulder 550. Both the external body or mandrel 510 and the plugelement or end shoulder 550 can be composed of a dissolvable material,as disclosed herein, and they can be composed of the same or differentmaterial. The plug element 550 is attached to the body 510 using thread,pins, drive wire, etc. or other fastener 556. A seal 554 on the nose ofthe plug element 550 can be composed of elastomer or the like.

The exterior of the body 510 has a sealing element 520 and an anchorelement or slip 530. The sealing element 520 can be composed ofelastomer, metal, or the like that is disposed, bonded, or affixed aboutthe exterior of the body 510. The anchor element or slip 530 can includeslip members, carbide inserts, gripping material, etc. attached aboutthe exterior of the body 510.

A setting tool 30 couples to the plug 500 and is used for running andsetting the plug 500 downhole in casing 10. Most setting tools use apull rod and an outer sleeve. The pull rod is attached to the center ofthe tool that is being set, typically a bridge plug or packer, and theouter sleeve pushes on the outer components, such as slips, cones, andpacking element. By using a cross-link device as shown in FIGS. 11A-11B,the push-pull relationship can be reversed in the setting tool 30.Therefore, the pull rod 36 is attached to the outer portions (i.e., body510) of the plug 500, while the outer sleeve 32 is linked to a push rod34 that acts on the center (i.e., plug element 550) of the plug 500.This action allows the setting tool 30 to force the plug element 550made of ordinary dissolvable or non-dissolvable material to expand thebody 510 of the plug 500 and actuate the external sealing element 520and anchor element 530.

As shown, the setting tool 30 includes a pull rod 36 with a distal heador cone 50 engaged inside the body 510. A push sleeve 32 engages theexternal body 510 and can attach thereto by shearable connection (notshown) or the like. Instead of attaching by a shearable connection, thesetting tool 30 can engage the body 510 in another fashion. The pushsleeve 32 is normally part of a setting adaptor kit that features acoarse adjustment thread that allows the longitudinal position of thepush sleeve 32 to be varied in a way that takes all slack out of thesystem, and permits the full useful travel of the setting tool 30 tocome into play. In this design, the push sleeve 32 is adjusted until thelower portion of inner passage 512 is firmly up against theupward-facing expansion face of the distal head 50. This wouldeffectively secure the plug 500 in place until it was expanded.

The distal head or cone 50 has a clearance fit with the inside dimensionof the body 510 above and below the inner passage 512. Once the distalhead 50 has passed through the inner passage 512, engaging both thesealing element 520 and the anchor element 530, the distal head or cone50 will pass into the upper portion of the body 510, where it is free tobe retrieved from the well.

The pull rod 36 and push sleeve 32 connect to an actuator (not shown) ofthe setting tool 30, which can pull the rod 36 and push the sleeve 32relative to one another. During this activation, the expansion head orcone 50 is forced through the inner passage 512 of the body 510, causingthe body 510 to expand outward toward the surrounding casing 10. Thehead 50 is pulled through the narrower portion of the body 510 so thatthe sealing element 520 and anchor element 530 engage the surroundingcasing wall 12, as shown in FIG. 12B. The head 50 can have a bypass 52therethrough to facilitate the pulling of the head 50 against anytrapped volume behind the head 50.

Meanwhile, the plug element or end shoulder 550 can seal the body'spassage 512 in both uphole and downhole directions and allow the plug500 to act as a bridge plug. As an alternative, the plug element 550 caninclude a one-way valve (i.e., ball and seat) so that flow can beallowed from downhole to uphole, but prevented from uphole to downhole.After setting and use, the components of the plug 500 can dissolve inthe manner disclosed herein to remove the fluid isolation.

As shown, the plug 500 of FIGS. 12A-12B has a body 510 and plug element550 that are separate components. This can facilitate assembly, but maynot be necessary. Instead, the body 510 and plug element 550 can beformed as one unit of dissolvable material. Because the inner passage512 of the body 510 has a narrow portion, the head 50 of the settingtool 30 can be an assembleable cone that installs inside the body 510.Such a cone for the head 50 can use interlocking segments, collet withsupportive core, or other type of assembly.

FIGS. 13A-13B illustrate cross-sectional views of a thirteenthself-removing plug 500 according to the present disclosure during stagesof setting in tubing 10. The plug 500 is a reverse arrangement of theplug in FIGS. 11A-11B. The plug 500 includes an external body or mandrel510 and an internal plug element or cone 550. Both the body 510 and plugelement 550 can be composed of a dissolvable material, as disclosedherein, and they can be composed of the same or different material. Theexterior of the body 510 has a sealing element 520 and an anchor elementor slip 530. The sealing element 520 can be composed of elastomer,metal, or the like that is disposed, bonded, or affixed about theexterior of the body 510. The anchor element or slip 530 can includeslip members, carbide inserts, gripping material, etc. attached aboutthe exterior of the body 510. A seal 554 on the nose 552 of the plugelement or cone 550 can be composed of elastomer or the like.

A setting tool 30 couples to the plug 500 and is used for running andsetting the plug 500 downhole in casing 10. The setting tool 30 includesa pull rod 34 with a distal end engaged with the plug element 550 by ashear connection 35. A push sleeve 38 engages the end of the plug's body510.

The pull rod 34 and push sleeve 38 connect to an actuator 40 of thesetting tool 30, which can pull the rod 34 and push the sleeve 38relative to one another. During this activation, the plug element 550 isforced through the inner passage 512 of the body 510, causing the body510 to expand outward toward the surrounding casing wall 12. The plugelement 550 is pulled into the narrower end of the body 510 at leastuntil the sealing element 520 and anchor element 530 engage thesurrounding casing wall 12, as shown in FIG. 13B. The nose 552 of theplug element 550 eventually seals inside the narrow head (or endshoulder) of the body 510, which has an opening 514 through which thepull rod 34 can pass. Eventually, the shear connection 35 of the pullrod 34 to the plug element 550 breaks free so that the setting tool 30can be removed from the plug 500.

The plug element 550 can be fitted with a body lock ring, a snap ring,or other retainer 556 to prevent the pulled plug element 510 from beingforced out of the body 510 in the opposite direction. This allows thedeployed plug 500 to seal the casing 10 as a bridge plug, preventingfluid flow in both uphole and downhole directions. After setting anduse, the components of the plug 500 can dissolve in the manner disclosedherein to remove the fluid isolation.

The expandable plugs 500 disclosed herein such as in FIGS. 11A through13B can be set conventionally on either an electric line, a hydraulicsetting tool, or the like. The plugs 500 may be either dissolvable ornon-dissolvable. As can be seen in the above embodiments of FIGS.11A-11B and 13A-13B in particular, the core (i.e., the plug element 550)of the plugs 500 remains behind and is firmly underneath the externalsealing element 520 and anchor element 530, backing them up in theexpanded position. This means that the plug 500 is not expected to beeffected by collapse pressure because the plug 500 is solid and thesealing and anchor elements 520 and 530 are solidly backed up. Thesqueeze on the sealing element 520 will be maintained, and the anchorelement 530 will remain solidly engaged. As mentioned, the plug element550 may be fitted with a lock ring, snap ring, or some other anti-returndevice that solidly links the body 510 and the plug element 550 togetherafter setting travel has been achieved to allow the plug 500 to holdpressure from both directions.

In each of the above embodiments of FIGS. 11A through 13B, it ispossible to vary the outside dimension of the plug element 550 toachieve different expansion ratios, depending on the weight or insidedimension of the casing 10 that the plug 500 is being expanded into. Asingle body 510 for the plugs 500 could be expanded into any number ofweight ranges of the same size of casing, simply by changing thediameter of the plug element 550 or expander 50. In fact, the plugelement 550 can be readily machined. Therefore, it could be initiallymade to a maximum size, corresponding to expansion in the lightestcasing weight. The element 550 can then be adjusted as required bymachining at the local level in the field according to operationalrequirements. Because the plug element 550 only has to survive oneexpansion, it is not necessary to use a more robust metallurgy seen inconventional expansion cones. It should also be noted that the insidedimension of the body 510 could be varied to accomplish the same thing.Finally, although the FIGS. 11A through 13B shows a plug body 510 thatappears to be of uniform wall thickness, this is not strictly necessary.It may be advantageous to vary the wall thickness in certain placesdepending on the implementation.

In the above embodiments of FIGS. 11A-11B and 13A-13B, the shear device39 that links the plug's body 510 to the setting tool 30 or the sheardevice 35 that links the plug element 550 to the setting tool 30 isselected to be stronger than the expansion force required to activatethe sealing element 520 and anchor element 530. When the plug element550 reaches an appropriate distance in the inner cavity 512 of theplug's body 510, the shear device 35, 39 will take the full load of thesetting tool 30 until it breaks. At that time, the setting tool 30,leaving the plug 500 in the set position as shown in FIGS. 11B & 13B. Asmentioned, the shear device 35, 39 may be pins, a shear sleeve, shearwire, or a fracture groove machined into the plug's body 510 or the plugelement 550 itself, to eliminate leaving any of these components in thewell. In the present case, if both the plug's body 510 and the plugelement 550 are made from dissolvable material, not much will be leftbehind.

Having an understanding of at least some of the various plugs disclosedherein, discussion turns to one type of operation in which the disclosedplugs can be used. FIGS. 14A-14C illustrate an example of aplug-and-perf operation that can use the disclosed self-removing plugs.Such a plug-and-perf operation can be used for fracturing zones of aformation. An assembly 60 is deployed into the wellbore 4 using awireline 62. Assistance may be provided from a fracture pump (not shown)that pumps displacement fluid (not shown) just before the assembly 60has been inserted into the wellbore 4. Pumping of the displacement fluidmay increase pressure in the inner casing bore. If this is the first runinto the casing 10, pumping of the fluid can also create a differentialsufficient to open a toe sleeve (not shown) of the inner casing string10. Once the toe sleeve has been opened, the assembly 60 may be insertedinto the wellbore 4 and continued pumping of the displacement fluid maydrive the assembly 60 to a setting depth below a production zone Z.Meanwhile, the displaced fluid may be forced into a lower formation viathe open toe sleeve.

Once the assembly 60 has been deployed to the setting depth, thedisclosed plug 100 (shown here as that of FIGS. 1A-1D) is set bysupplying a signal (e.g., electricity at a first polarity) to theassembly 60 via the wireline 62 to activate a setting tool 66. Asdiscussed above, the setting tool 66 may use a number of differentcomponents depending on the type of plug 100 being deployed and whetherthe plug 100 includes a permanent mandrel or not. In this example, thesetting tool 66 drives a sleeve 22 toward a mule shoe 28 while a settingmandrel 26 restrains the plug 100, thereby compressing the elements ofthe plug 100 into engagement with the casing 10.

As shown in FIG. 14B, a tensile force can then be exerted on theassembly 60 by pulling the wireline 62 from the surface to release theplug 100 from the assembly 60. In the present example, the mule shoe 28can shear free of the setting mandrel 26. As the mule shoe 28 falls inthe wellbore 4, the assembly 60 is then raised using the wireline 62until the perforation guns 64 are aligned with the production zone Z. Asignal (e.g., electricity at a second polarity) can then be resuppliedto the assembly 60 via the wireline 62 to fire the perforation guns 64into the casing 10, thereby forming perforations 15. Once theperforations 15 have been formed, the assembly 60 may be retrieved to alubricator (not shown) at surface using the wireline 62. A shutoff valveat the lubricator may then be closed.

As shown in FIG. 14C, a ball B or the like may then be released from alauncher (not shown) at the surface, and fracturing fluid may be pumpedinto the wellbore 4. As is known, the fracturing fluid may be a slurryincluding: proppant (i.e., sand), water, and chemical additives.Continued pumping of the fracturing fluid may drive the ball B towardthe plug 100 until the ball B lands onto the plug 100, thereby closingoff fluid flow through the plug 100.

Continued pumping of the fracturing fluid may exert pressure on theseated ball B until pressure in the casing 10 increases to force thefracturing fluid (above the seated ball B) through the perforations 15and the cement 14 and into the production zone Z to create fractures. Asis known, the proppant in the fracturing fluid may be deposited into thefractures. Pumping of the fracturing fluid may continue until a desiredquantity has been pumped into the production zone Z.

Once the fracturing operation of the zone Z has been completed,additional stages can be fractured by repeating the above steps furtherup the wellbore 4.

In the above arrangement, the ball B is deployed from a launcher at thesurface after the assembly 60 has been removed. Other arrangements arepossible. For example, FIG. 15 shows an embodiment of the assembly 60run in hole and having a launcher 68 as part of the setting tool 66.After the plug 100 (shown here as that of FIGS. 2A-2D with a mandrel160) is set in the casing 10, the assembly 60 is lifted, and thelauncher 68 releases the ball B to land in the plug 100. Release fromthe launcher 68 can be triggered by a signal through the wireline 62, byrelease of the setting tool 66 from the plug 100, or other mechanism.

Eventually, as shown in FIG. 16, the wellbore 4 may be cleared once thedisclosed plugs 100 dissolve, corrode, degrade, etc. in the casing 10due to wellbore conditions, introduced agents, etc., as describedherein.

FIGS. 17A through 19 illustrate cross-sectional views of anotherself-removing plug 100 according to the present disclosure during stagesof setting in tubing 10. This plug 100 is similar to that disclosedabove with reference to FIGS. 2A-2E, for example, so that like referencenumerals are used for similar components. This plug 100 includes themandrel 160 that remains with the plug 100 after setting.

On this plug 100, the permanent mandrel 160 is attached to an innersetting tool (e.g., 24: FIG. 2A) of a running tool (e.g., 20: FIG. 2A)with a temporary connection, such as a shearable or releasable thread.With the setting forces applied, the running tool (20) can eventuallyshear free of the permanent mandrel 160 which remains as part of theplug 100.

As shown in FIGS. 17A-17B, the plug 100 includes a contact or push ring170 disposed on the mandrel 160 against which the setting sleeve (22)presses during setting procedures. The plug 100 also includes cones110A-B, slips 120A-B, and a seal element (i.e., expansion element orrings 150A-B) movably disposed on the mandrel 160 and includes a muleshoe 168 affixed to the mandrel's distal end.

As with other embodiments, this plug 100 is self-removing. For example,the cones 110A-B, slips 120A-B, expansion rings 150A-B, mandrel 160,contact rings 170, mule shoe 168, and the like can be composed of areactive metal, degradable composite polymer, or other self-removingmaterial. If used on the disclosed plug 100, slip inserts 124 of theslips 120A-B can be composed of ductile iron, while any seals, pump-downrings, etc. can be composed of elastomer.

For run in as shown in FIGS. 17A-17B, the components 110A-B, 120A-B, and150A-B fit on the mandrel 160 in an uncompressed state between themovable contact ring 170 and the fixed mule shoe 168. As best shown inthe detail of FIG. 17B, the cones 110A-B of the plug 100 have inclines112 against which the opposing slips 120A-B can wedge. The other end ofthe downhole slip 120A abuts against the mule shoe 168, which is used topush the slip 120A on the incline 112 during setting. In a similarfashion, the uphole slip 120B abuts against the contact ring 170, whichis used to push the slip 120B on the incline 112 during setting.

The expansion rings 150A-B are disposed between complementary inclinedends 114 of the opposing cones 110A-B. (As such, the cones 110A-B act ina similar fashion to the body rings discussed previously with respect toFIGS. 1A through 2E, for example.) The outside surfaces of the expansionrings 150A-B can define wicker profiles or angled fins to enhanceengagement with a surrounding casing wall 12. As shown, the expansionrings 150A-B preferably includes two adjacent split C-rings that canslide relative to one another as they expand outward. The splits inthese rings 150A-C are misaligned so that the two split rings 150A-Btogether form a complete ring. Although only one set is shown here,multiple sets of such expansion rings 150A-B can be used adjacent oneanother to increase the overall surface area of their engagement withthe surrounding casing wall 12.

During run-in as shown in FIGS. 17A-17B, the components 110A-B, 120A-B,and 150A-B are held on the mandrel 168 uncompressed. The running tool(20) is coupled to an actuator (not shown) used for activating thesetting tool (20) and setting the plug 100. During activation, thesetting sleeve (22) pushes against the contact ring 170 to compress thecomponents, while the inner setting tool (24) pulls the mandrel 160 inthe opposite direction. As a result, the mule shoe 168 concurrentlypushes against the slips 120A to compress the components on the mandrel160.

As shown in a set state of FIGS. 18A-18B, the opposing slips 120A-B arepushed up the inclines 112 and wedged against the inside wall 12 of thecasing 10. At the same time, the expansion rings 150A-B are forcedoutward toward the surrounding casing 10 to form a metal-to-metal sealwith the inner casing wall 12. During setting, the cones 110A-B sandwichthe expansion rings 150A-B.

As best shown in FIG. 18B, the abutting inclined ends 114 of the cones110A-B tend to come closer in proximity to one another, especially inthe larger inner dimension of casing 10 depicted here. One or both ofthese inclined ends 114 includes a seal 115 in the form of a lip, tab,cup, extension, ring, or the like that can seal off fluid communicationbetween the cone 110A and the outside of the mandrel 160.

In this embodiment, the lip 115 is disposed on the uphole end of thedownhole cone 110A and may tend to seal of fluid pressure uphole thereoffrom passing downhole through the space between the cone 110A and themandrel 160. A comparable lip (not shown) can be disposed on the upholeend of the uphole cone 110B to prevent fluid communication in the samedirection. Moreover, the downhole ends of one or both cones 110A-B canhave such a seal feature to prevent fluid downhole of the plug fromcommunicating uphole in the space between the cones 110A-B and mandrel160. As an additional alternative, the mandrel 160 may include one ormore external seals (not shown) disposed thereabout for sealing againstthe inside of the cones, such as the downhole cone 110A. These and otherforms of sealing features can be used.

Eventually during setting, the setting force shears the setting tool(20) free of the mandrel 160. At this point, a ball (not shown) or otherplugging element can be deployed to the plug 100 to seat against theseating surface 164 of the mandrel 160. Pressure for a fracturetreatment can be applied against the plug 100 with the seated ball,which prevents the treatment from passing to zones further downhole.

For illustrative purposes, FIG. 19 shows setting of the plug 100 withina heavier weight of the same size casing 10 than shown in FIGS. 18A-18Bsuch that the inner dimensions are different. The heavier casing 10 hasa smaller inner dimension than in FIGS. 18A-18B. Still, the slips 120A-Band expansion rings 150A-B are compressed out from the mandrel 160 toseal against the casing 10 in a comparable manner as before.

Although not explicitly shown in FIGS. 17A through 19, a locking orretention feature can be used on the plug 100 to hold the set components(i.e., 110A-B, 120A-B, 150A-B) in their compressed state in a fixedposition on the mandrel 160. For example, a body lock ring, serrations,ratchet mechanism, or the like can be used between the contact ring 170and the mandrel's outer surface to hold the ring 170 in place.

Alternatively, the mandrel 170 may be free to slid relative to the setcomponents (i.e., 110A-B, 120A-B, 150A-B), as with other embodimentsdisclosed herein. In such a case, pressure for a fracture treatmentapplied against the plug 100 with a ball seated in the mandrel's seatingsurface 164 will shift the mandrel 160 downhole through the setcomponents (i.e., 110A-B, 120A-B, 150A-B). A shoulder 165 on the mandrel160 can engage the contact ring 170 and tend to compress the setcomponents. Meanwhile, the downhole slip 120A (with its inserts 124 ifpresent) and the expanded expansion rings 150A-B would tend to preventmovement of the plug 100 downward in the casing 10. In general, thedownhole slip 120A may be larger than the uphole slip 120B based on thepurpose of the plug 100 to isolate fluid pressure primarily from a zoneabove the plug 100 to a zone below. Other arrangements, however, couldbe used.

Finally, the plug 100 of FIGS. 17A through 19 can be readily modified toinclude the mandrel 160 as removable in a manner similar to otherembodiments disclosed herein. In such an instance, the mule shoe 168 maybecome unfixed from the temporary mandrel 160 during setting. The setcomponents (i.e., 110A-B, 120A-B, 150A-B) can remain in their compressedstate in a fixed position in the casing, and a ball can be landed on aseating area associated with the contact ring 170. These and other suchmodifications could be made to the disclosed plug 100.

As noted above, the plug 100 disclosed above can have expansion rings150A-B to create a seal with the surrounding tubular. Because the rings150A-B are preferably composed of metal as disclosed herein, the sealcan be a metal-to-metal seal according to the present disclosure.

FIGS. 20A-20C illustrate further details of expansion rings 150A-Bdisposed between the cones 110A-B on the mandrel 160 for the disclosedplug 100. As shown in FIG. 20A, the expansion rings 150A-B includetongue and groove features 152A-B so they can be held adjacent oneanother as they are expanded outward when the cones 110A-B are broughttogether. As noted above, the external surface of the rings 150A-B caninclude wickers 154 or the like to facilitate sealing with thesurrounding tubular (not shown). As depicted here, the wickers 154 maybe slanted or laid down in the form of radial fins to make a number ofcollapsible cup seals with the surrounding tubular when pressedthereagainst. Furthermore, the downhole ring 150A may have an edge fin156 that overlaps portion of the uphole ring 150B to close off fluidcommunication in the space between the rings 150A-B when the edge fin156 is pressed against the surrounding tubular.

Again, the downhole cone 110A includes the lip seal 115. Forillustrative purposes, the lip seal 115 is depicted in a relaxed stateto show how it expands inward from the inner diameter of the cone 110A.When actually placed against the mandrel 160, the lip seal 115 willnaturally be bent inward against the mandrel's outer surface and wouldhave an outline better depicted by the dashed line in FIG. 20A. In thisway, the downhole cone 110A can form a metal-to-metal seal with themandrel 160. The cone face 114 of the downhole cone 110A may include acoating, such as a flexible non-metallic or metallic material, to helpform a seal between the cone face 114 and the expansion ring 150A.

FIG. 20B illustrates a similar depiction of the details of the expansionrings 150A-B disposed between the cones 110A-B on the mandrel 160 forthe disclosed plug 100. As shown in FIG. 20B, the expansion rings 150A-Binclude the tongue and groove features 152A-B and the slanted wickers154. Also, the downhole ring 150A has the edge fin 156 that overlapsportion of the uphole ring 150B, and the cone face 114 can include acoating.

The uphole ring 150B in FIG. 20B includes a lip seal 155 on its innerdiameter in a similar manner to the lip seal 115 of the downhole cone110A. Rather than sealing with the mandrel 160, however, this lip seal155 on the ring 150B can help seal the gap between the expansion ring150B and cone face 114 of the downhole cone 110A when the rings 150A-Bare wedged and expanded outward.

FIGS. 21A-21B illustrate isolated perspective views of the expansionsrings 150A-B for the disclosed plug. To allow for expansion, each of therings 150A-B includes a split 151A-B. When the rings 150A-B are placednext to one another, the splits 151A-B are offset from one another toclose of a leak path. The downhole expansion ring 150A in FIG. 21Aincludes the tongue feature 152A partially thereabout. This feature 152Aslideably fits in the groove feature 152B in the uphole expansion ring150B of FIG. 21B. The tongue and groove features 152A-B not only helphold the rings 150A-B together, but can also create a seal between therings 150A-B to close of a leak path for fluid.

As discussed herein, the disclosed plug 100 is preferably self-removingso that it corrodes or otherwise disintegrates downhole. To helpaccelerate the corrosion rate, the plug 100 can have a number ofapertures, holes, and the like to allow fluid to access more surfacearea of some of the components while the plug 100 can maintain itsealing purpose. As shown in FIG. 22, for example, components such asthe cones 110A-B, mandrel 160, and mule shoe 168 can have holes 119 and169 in various places to allow fluid to access more surface area ofthese components and advance corrosion. Those components, such as theexpansion rings 150A-B and cone faces, intended for sealing will lacksuch holes. Additionally, those components, such as the slips 120A-B,intended for structural support may lack such holes so as to notjeopardize their function.

In previous embodiments, metal-to-metal sealing has been presented as aprimary means for sealing with the disclosed plugs. Such metal-to-metalsealing can be enhanced by using a degradable sealing material in theform of a coating, skin, wrap, etc. applied on, around, over, etc. oneor more of the components of the disclosed plugs 100. In one particulararrangement disclosed below, the expansion rings 150 have a degradable,flexible skin, coating, wrap or the like to bridge off micro-leak pathsbetween the casing 10, cone 110, expansion rings 150, and the like inthe metal-to-metal sealing of the disclosed plugs 100. The skin can be asprayed-on or a painted-on coating or can be molded on surfaces of theplug's components. For example, the skin can be applied to bothexpansion rings and may applied to the cone face.

In one arrangement, the flexible sealing skin is molded to shape andthen installed over (and between) the expansion rings 150 and/or othercomponents (e.g., cone 110) to contain any leakage. In anotherarrangement, the expansion rings 150 and/or other components (e.g., 110)are over-molded with the skin, such as with a degradable elastomer.

FIG. 23 illustrate a cross-sectional view of a self-removing plug 100with additional sealing for the expansion rings 150A-B according to thepresent disclosure. This plug 100 is similar to those disclosed above,for example, with reference to FIG. 17A so that like reference numeralsare used for similar components.

As shown in FIG. 23, the plug 100 includes a contact ring 170 disposedon a mandrel 160 against which a setting sleeve (22) presses duringsetting procedures. The plug 100 also includes cones 110A-B, slips 120,and expansion rings 150A-B movably disposed on the mandrel 160 andincludes a mule shoe 168 affixed to the mandrel's distal end.

As with other embodiments, this plug 100 is self-removing. For example,the cones 110A-B, slips 120, expansion rings 150A-B, mandrel 160,contact ring 170, mule shoe 168, and the like can be composed of areactive metal, degradable composite polymer, or other self-removingmaterial. If used on the disclosed plug 100, slip inserts 124 of theslips 120 can be composed of ductile iron, while any seals, pump-downrings, etc. can be composed of elastomer.

The expansion rings 150A-B on the plug 100 include a sealing skin orcoating 180 disposed/coated at least partially thereabout to bridge offmicro-leak paths between the casing 10, cone 110, expansion rings150A-B, and the like in the metal-to-metal sealing of the disclosed plug100. The sealing skin or coating 180 can include elastomer, rubber,degradable rubber, dissolvable rubber, and epoxy and can be appliedusing techniques discussed below.

In contrast, FIGS. 24A-24B illustrate cross-sectional views of aself-removing plug 100 with other sealing for the expansion 150A-B ringsaccording to the present disclosure during stages of setting in tubing.In this arrangement, portion of the cone 110A has a sealing skin 190disposed at least partially on its surface against which the expansionrings 150A-B ride to bridge off micro-leak paths between the cone 110Aand expansion rings 150A-B in the metal-to-metal sealing of thedisclosed plug 100.

FIG. 24C illustrates a similar depiction of the details of the expansionrings 150A-B disposed between the cones 110A-B on the mandrel 160 forthe disclosed plug 100. Here, the sealing skin 190 is disposed adjacentthe cone 110A and may have a lip or leg that extends into an open edge117A of the cone 110A. An additional crush ring 195 is also provided toenhance the seal and can be disposed in a cutaway or space 117B of thecone 110B. Like the sealing skin 190, the crush ring 195 can be made ofa degradable rubber or polymer. When the cones 110A-B are broughttogether and the expansion rings 150A-B expand outward, the crush ring195 and the sealing skin 190 can engage one another and seal the annulararea between the expansion rings 150A-B and the mandrel 160. As will beappreciated by these arrangements, various skins, rings, gaskets, andthe like can be disposed between one or both of the sides of theexpansion rings 150A-B and the inclines of the cones 110A-B to enhancesealing.

In one arrangement, the flexible sealing skins or coatings 180 and 190of FIGS. 23 and 24A-B are molded to shape and then installed over (andbetween) the components (e.g., the expansion rings 150A-B, cone 110A,etc.) to contain any leakage. In another arrangement, the components(e.g., expansion rings 150A-B, cone 110A, etc.) are over-molded with theskin or coating, such as with a degradable elastomer in an injectionmolding process.

As on example, FIG. 25 illustrates a cross-sectional view of componentsfor molding the additional sealing for the expansion rings 150A-B. Theupper and lower expansion rings 150A-B have a dissolvable sealing insert182 disposed between them, which can be composed of a dissolvableelastomer, rubber, or the like. The joined rings 150A-B fit in reliefs185 of bottom and top molds 184A-B. The top mold 184A has ports 187 forinjection and weeping of injected material for the skin 180 to be formedon the expansion rings 150A-B.

In particular, FIGS. 26A-26C illustrate steps of the molding process ofthe additional sealing for the expansion rings 150A-B. The components tobe molded are prepped by cleaning/degreasing, and the dissolvable insert182 is placed between upper and lower expansion rings 150A-B. Then, therings 150A-B and insert 182 are placed in the relief 185 of the bottommold 184B, and the top mold 184A is placed with its relief 185 on therings 150A-B, as shown in FIG. 26A. As arranged, the expansion rings150A-B in the bottom and top molds 184A-B have the insert 182 disposedbetween them and have exposed spaces communicating with the injectionports 187 in the molds 184A-B.

The molds 184A-B may be preheated and may have mold releasing agents.The coating material for the skin 180 is injection molded as shown inFIG. 26B. For example, dissolvable rubber may be injected into the molds184A-B or it can be compression molded by placing raw material aroundexpansion rings and then compressing together. The molds 184A-B areheated and/or compressed together for period of time.

Eventually, when the skin or coating 180 has been cured and set, theexpansion rings 150A-B are removed from the molds 184A-B as shown inFIG. 26C and have the dissolvable skin 180 molded thereover and between.Any excess material can be trimmed off to complete the molding process.

Referring to FIG. 26D, temporary pins 189 or other features may be addedto the mold (e.g., bottom mold 184B) for containing the expansion rings(e.g., 150B) during the over-molding operation. These pins 189 mayprevent radial movement of the rings 150A-B due to rubber compressionwhen molding.

Although the inner surfaces of the expansion rings 150A-B in FIG.26A-26D have the molded insert 182 between them, other arrangements maylack this portion. For example, FIG. 27A illustrates the expansion rings150A-B having the skin 180 primarily on outer surfaces, while the rings150A-B fit together with a metal-to-metal interface.

Additionally, although the wedged surface of only one of the expansionrings 150A-B and the outer contact surfaces of both rings 150A-B areshown having the skin or coating 180 in FIG. 26C, it will be appreciatedthat more or less of the rings 150A-B can be molded with the skin 180.For example, FIGS. 27A-27B show how more or most of both wedged surfaceson the two rings 150A-B can have portion of the molded skin or coating180.

Finally, although previous arrangements may have shown either theexpansion rings 150A-B having the skin 180 (FIG. 23) or have shownanother component (e.g., cone (e.g., cone 110A) having the skin 190(FIGS. 24A-B), it will be appreciated that the various arrangements canbe combined. For example, FIG. 27C shows a combination of the expansionrings 150A-B having the disclosed skin 180 along with a skin insert 190disposed on the cone 110A, primarily at the cone's inner wedged surfaceagainst which the expansion rings 150A-B ride. These and othercombinations disclosed herein can be used for a particularimplementation.

FIGS. 28A and 28B illustrate views of a self-removing plug 100 with analternative seal element 600 according to the present disclosure. Theplug 100 includes a mandrel 160 having a mule shoe 168, slips 120, aslip cone 110, and the seal element 600 disposed thereon. As before, oneor more and preferably most of the components are composed of adissolvable material. The slips 120 may be retained circumferentially byone or more bands 124 and may be held longitudinally on the mandrel 160with pins 122. The cone 110 may also be held longitudinally on themandrel 160 with pins 111. These retaining pins 122, 111 and bands 124may prevent premature setting.

The seal element 600 includes a push cone 610 moveable on the end of themandrel 160 and includes expansive petal rings 620, 630 sandwichedbetween the push cone 610 and the slip cone 110. For reference, FIG. 29illustrates an isolated view of the push cone 610 and the expansivepetal rings 620, 630 of the alternative sealing system 600.

The expansive petal rings 620, 630 respectively have petals 622, 632that arrange offset from one another to seal off potential leak pathsbetween them. To keep the offset orientation, pins 625 either integralor added to one of rings 620 affix between the rings 620, 630. The innerexpansion ring 630 adjacent the slip cone 110 may have an inner lip 635extending partially under the slip cone 110 to seal off internal leakpaths.

As expected, setting of the plug 600 involves forcing the push cone 610along the mandrel 160 against the expansion rings 620, 630, the slipcone 110, and slips 120, which are ultimately held against the lowershoulder of the mule shoe 168 or other part of the mandrel 160.Additional components as disclosed herein may be provided on the plug100, such as body lock rings and other components above the push ring610.

As depicted in FIG. 29, sealing can be enhanced by coating the cone faceof the push cone 610 with a flexible material. Alternatively, the pushcone 610 can be composed of a flexible, dissolvable material. The pedals622, 632 of the expansion rings 620, 630 can also be coated withflexible material to help seal.

As disclosed herein, various types of slips can be used for thedisclosed plugs. As shown in previous examples of FIGS. 1D, 2D-2E, etc.,the slip 120 can be a solid ring. As shown in previous examples of FIGS.3E, 4E, etc., the slip 220 can be a ring with separations 221,divisions, or the like to facilitate separation at various points. Asshown in FIG. 30A, the slip 120 can include a ring having inserts 124disposed about its face. The ringed slip 120 can have various slits ordivisions 121 making partial segments 122. The cone 110 can have flats111 to engage the segments 122.

In other variations, the slip can be an assembly of several bodies,elements, or segments. As shown in FIG. 30B, the segment 122 of the slip120 can have inserts or buttons 124 disposed in the face to engagecasing. The individual segments 122 such as this can be held in a ringaround a mandrel of the plug using retention bands or the like (notshown). As an alternative shown in FIG. 30C, the segment 122 of the slip120 can have a wicker surface 126 for engaging casing. These and otherarrangements can be used.

The surface of the slip, such as the wicker surface 126 of the segment122 in FIG. 30C, can have a thermal spray coating on the dissolvablematerial of the slip 120. The coating can help the wicker surface 126engage the casing wall. In general, the coating can be a nickel (Ni)based tungsten carbide (WC) material applied by a thermal spray process,such as high velocity oxygen fuel spraying (HVOF). Alternatively, thecoating can be a ceramic-based coating. Details related to particulartypes of coatings can be found in U.S. Pub. Nos. 2014/0216722 and2014/0216723, which are incorporated herein by reference. Use of thecoating can eliminate the need for inserts or buttons and can minimizethe amount of non-dissolvable material to be left behind.

In the various embodiments disclosed herein, various components aredescribed as dissolving. How this is achieved depends on the type ofmaterials involved and what conditions or the like the material aresubjected to. In general, the dissolvable materials disclosed herein canbe a reactive metal that “dissolves” in the well conditions. Dissolvingas disclosed herein can, therefore, refer to corrosion of a reactivemetal in the well conditions. Other forms of dissolving can be used forthe various materials of the disclosed plugs. For example, an acid orother chemical may “dissolve” the plugs by breaking down the materialsof the plugs and thereby “dissolve” the plug. The materials of the plugcan “dissolve” by eroding or breaking apart in the well conditions. Thematerials of the disclosed plugs can “dissolve” by melting, degrading,eroding, etc. in the well conditions. Dissolving rates can be adjustedfrom hours to days by modifying the composition, thickness, and the likeof the components for the plugs, by adding coatings to the components,altering well conditions, applying a trigger chemical, etc.

As noted above with reference to FIGS. 1A-1D, the slip 120, the sealingsleeve 130, and the expansion rings 150A-B in one configuration aremanufactured from a ductile/high elongation dissolvable material, andthe material's elongation properties can be in the range of 18-28%, butcan be slightly more or less. Accordingly, a number of components in thevarious embodiments may be similarly configured. For example, components120, 130, 150, 220, 230, 330, 360, 366, 420, 434, 436, 510, 620, 630,etc. in the various arrangements disclosed herein can be manufacturedfrom a ductile/high elongation dissolvable material. Moreover, thematerial's elongation properties can be in the range of 18-28%, but canbe slightly more or less.

The foregoing description of preferred and other embodiments is notintended to limit or restrict the scope or applicability of theinventive concepts conceived of by the Applicants. It will beappreciated with the benefit of the present disclosure that featuresdescribed above in accordance with any embodiment or aspect of thedisclosed subject matter can be utilized, either alone or incombination, with any other described feature, in any other embodimentor aspect of the disclosed subject matter.

In exchange for disclosing the inventive concepts contained herein, theApplicants desire all patent rights afforded by the appended claims.Therefore, it is intended that the appended claims include allmodifications and alterations to the full extent that they come withinthe scope of the following claims or the equivalents thereof.

What is claimed is:
 1. A downhole apparatus for use in a tubular, theapparatus comprising: a mandrel having a first end shoulder; a firstslip disposed on the mandrel adjacent the first end shoulder; a conedisposed on the mandrel adjacent the first slip and movable relative tothe first end shoulder to engage the first slip toward the tubular; aseal element disposed on the mandrel adjacent the cone, at least aportion of the seal element composed of a dissolvable metallic materialand being expandable outward from the mandrel, the expanded portion ofthe seal element forming a metal seal against the tubular and sealingoff fluid communication in the annular space between the seal elementand the tubular.
 2. The apparatus of claim 1, wherein the first endshoulder is disposed on the mandrel and is removable therefrom inresponse to a predetermined load.
 3. The apparatus of claim 2, whereinthe mandrel freed of the first end shoulder is removable from the slip,the cone, and the seal element.
 4. The apparatus of claim 3, wherein theseal element defines a seating area engageable by a plug deployed downthe tubular to the apparatus; or wherein the cone defines a seating areaengageable by a plug deployed down the tubular to the apparatus.
 5. Theapparatus of claim 1, wherein the first end shoulder is disposed towarda first end of the mandrel, wherein the mandrel has a second endshoulder disposed at a second end adjacent the seal element, wherein themandrel defines a through-bore from the first end to the second end, andwherein the second end defines a seating area about the through-bore,the seating area engageable by a plug deployed down the tubular to theapparatus.
 6. The apparatus of claim 1, wherein the seal elementcomprises: first and second rings disposed on the mandrel and movablelongitudinally thereon; an expansion ring disposed on the mandrelbetween the first and second rings and expanding radially outward withthe longitudinal movement of the first and second rings toward oneanother.
 7. The apparatus of claim 6, further comprising: a sheathdisposed circumferentially about at least the expansion ring, the sheathdeforming outward toward the tubular with the radial expansion of theexpansion ring.
 8. The apparatus of claim 7, further comprising asealing ring bonded circumferentially about the sheath and engageableagainst the tubular; and/or wherein the first ring is integrally part ofthe cone.
 9. The apparatus of claim 7, wherein the sheath comprises oneor more lips extending at least between the first ring and the cone, atleast between the second ring and a push ring disposed on the mandrel,or between the first ring and the cone as well as the second ring andthe push ring.
 10. The apparatus of claim 7, wherein the first andsecond rings, the expansion ring, and the sheath are each composed of areactive metal.
 11. The apparatus of claim 6, wherein the first ringdefines a first inclined face, the second ring defines a second inclinedface opposing the first inclined face, the expansion ring having firstand second inclined sides disposed respectively against the first andsecond inclined faces.
 12. The apparatus of claim 11, wherein theexpansion ring comprise first and second split rings interlockedtogether and each having one of the first and second inclined sides. 13.The apparatus of claim 12, wherein the expansion ring comprises anelastomeric material disposed at least between the first and secondinterlocked split rings.
 14. The apparatus of claim 11, furthercomprising: a first elastomeric element disposed adjacent the firstinclined face of the first ring and engageable with the first side;and/or a second elastomeric element disposed adjacent the secondinclined face of the second ring and engageable with the second side.15. The apparatus of claim 14, wherein the first elastomeric elementcomprises a lip disposed in an edge of the first ring and at leastpartially engaging the mandrel; and/or wherein the second inclined facedefines a cutaway accommodating the second elastomeric element.
 16. Theapparatus of claim 11, wherein the expansion ring defines an externalsurface disposed circumferentially thereabout and engageable toward thetubular, the external surface comprising a plurality of fins extendingtherefrom.
 17. The apparatus of claim 11, wherein the second inclinedface defines a cutaway accommodating portion of the first inclined facemoved longitudinally toward the second inclined surface.
 18. Theapparatus of claim 11, wherein the first inclined face defines a lipengageable against the mandrel.
 19. The apparatus of claim 6, furthercomprising: a second slip disposed on the mandrel adjacent the secondring; and a second end shoulder disposed on the mandrel adjacent thesecond slip and movable toward the first end shoulder to engage thesecond slip toward the tubular.
 20. The apparatus of claim 19, whereinthe second ring comprises a body lock ring engageable with a portion ofthe mandrel.
 21. The apparatus of claim 1, wherein the seal elementcomprises: a push ring disposed on the mandrel and movablelongitudinally thereon; an expansion ring disposed on the mandrelbetween the push ring and an inclined face of the cone and expandingradially outward with the longitudinal movement of the push ring and thecone toward one another; and a sheath disposed circumferentially aboutat least the expansion ring and having a lip extending at least towardthe push ring, the sheath deforming outward toward the tubular with theradial expansion of the expansion ring.
 22. The apparatus of claim 1,wherein the seal element is disposed about the cone and against an endof the first slip, the seal element expandable along an incline of thecone.
 23. The apparatus of claim 1, wherein the first slip is disposedagainst a first incline of the cone, wherein the seal element isdisposed about a second incline of the cone opposed to the secondincline, and wherein the seal element is expandable along the secondincline of the cone.
 24. The apparatus of claim 1, wherein the mandreldefines a first incline; wherein the seal element is expandable alongthe first incline of the mandrel; wherein the cone defines a secondincline opposing the first incline, wherein a setting element disposedbetween the first slip and the seal element concurrently expands thefirst slip and the seal element along the respective incline and isfrangible in response to a predetermined load thereagainst.
 25. Theapparatus of claim 24, wherein the seal element comprises a swage sealhaving: a ring body composed of the dissolvable metallic material; andinner and outer seal members disposed respectively about the inner andouter circumferences of the ring body.
 26. The apparatus of claim 1,wherein the seal element comprises: a first ring disposed on the mandreladjacent the cone, the first ring having first petals flexible outwardtherefrom, the first ring having a lip disposed at least partiallybetween the cone and the mandrel; a second ring disposed on the mandreladjacent the first ring and having second petals flexible outwardtherefrom; and a push cone disposed on the mandrel adjacent the secondring and being moveable longitudinally on the mandrel toward the firstend shoulder.
 27. The apparatus of claim 26, wherein at least one ormore of the first ring, second ring, and push cone comprises a coatingof elastomeric material.
 28. The apparatus of claim 1, wherein themandrel is an expandable sleeve; wherein the first slip is disposed onan outer surface of the expandable sleeve; wherein the seal element isdisposed on the outer surface of the expandable sleeve; and wherein thecone is disposed in the expandable sleeve, the cone movable toward thefirst end shoulder to expand the expandable sleeve and engage the firstslip and the seal element toward the tubular.
 29. The apparatus of claim28, wherein the first end shoulder comprises an at least partiallyclosed end of the expandable sleeve, the cone having a portion sealablyengaging the at least partially closed end; or wherein the cone isremovable from the expandable sleeve.
 30. The apparatus of claim 1,further comprising: a perforating gun running into the tubular andoperable to perforate the tubular; and a running tool extending from theperforating gun and temporarily affixable to the apparatus, the runningtool being operable to set the apparatus in the tubular.
 31. Theapparatus of claim 1, wherein the dissolvable metallic material isselected from the group consisting of a reactive metal; a magnesiumalloy; and calcium, magnesium, and aluminum including alloying elementsof calcium, magnesium, aluminum, lithium, gallium, indium, zinc, andbismuth.
 32. The apparatus of claim 1, wherein one or more components ofthe apparatus other than the seal element are composed of one or more ofa reactive metal, a degradable composite polymer, a self-removingmaterial, and an elastomeric material.
 33. A downhole apparatus for usein a tubular, the apparatus comprising: a mandrel having a first endshoulder; a first slip disposed on the mandrel adjacent the first endshoulder; a cone disposed on the mandrel adjacent the first slip andmovable relative to the first end shoulder to engage the first sliptoward the tubular; a seal element disposed on the mandrel adjacent thecone, at least a portion of the seal element composed of a dissolvablemetallic material, at least partially coated with a coating material,and being expandable outward from the mandrel, the expanded portion ofthe seal element forming a metal seal against the tubular and sealingoff fluid communication in the annular space between the seal elementand the tubular.
 34. The apparatus of claim 33, wherein the coatingmaterial is selected from the group consisting of elastomer, rubber,degradable material, dissolvable material, and epoxy.